Refrigerator and full ice level sensing apparatus thereof

ABSTRACT

A refrigerator and an ice level sensing apparatus are provided. The refrigerator may include a main body, and an ice level sensing apparatus including an optical element for sending or receiving a signal, and an alignment device for aligning and maintaining alignment of the optical element in a preset direction. The sensing apparatus may sense whether an ice storage container in which ice cubes made by an ice maker is at a full ice level. The optical element may be aligned at a preset position, thus preventing movement of the optical element, resulting in improved reliability of the sensing apparatus.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. §119(a), this application claims the benefit of an earlier filing date and right of priority to Korean Application No. 10-2009-0014067, filed in Korea on Feb. 19, 2009, and is a Continuation-In-Part application of U.S. application Ser. Nos. 12/423,118 filed Apr. 14, 2009, 12/423,170 filed Apr. 14, 2009, 12/423,256 filed Apr. 14, 2009, 12/433,944 filed May 1, 2009, 12/470,615 filed May 22, 2009 and 12/471,048 filed May 22, 2009, respectively claiming priority to Korean Applications Nos. 10-2008-0034854 filed in Korea on Apr. 15, 2008, 10-2008-0034856 filed in Korea on Apr. 15, 2008, 10-2008-0034862 filed in Korea on Apr. 15, 2008, 10-2008-0041084 filed in Korea on May 1, 2008, 10-2008-0049345 filed in Korea on May 27, 2008 and 10-2008-0049346 filed in Korea on May 27, 2008, the entirety of which is incorporated herein by reference.

BACKGROUND

1. Field

This disclosure relates to an ice level sensing apparatus for a refrigerator.

2. Background

A refrigerator refrigerates or freezes food items or the like to keep them fresh in storage. The refrigerator includes an ice maker for making ice and an ice container to receive ice made by the ice maker.

A full ice detection lever, a mechanical device, coupled to a controller detects whether or not the ice container is full of ice. The full ice detection lever positioned at a lower side and rises as high as the ice is accumulated in the ice container. When the full ice detection lever rises by more than a certain height due to ice accumulation, the controller determines that the ice container is full. However, in the related art, if the full ice detection lever becomes frozen, the mechanical operation of the full ice detection lever is not likely to be performed, and the controller cannot determine whether the ice container is full. In such faulty state, ice is continuously supplied, causing an overflow of ice from the ice container.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:

FIG. 1 is a perspective view of a refrigerator in accordance with an embodiment as broadly described herein;

FIG. 2 is an enlarged perspective view of an ice maker and a full ice level sensing apparatus of the refrigerator shown FIG. 1;

FIG. 3 is a sectional view of the ice maker shown in FIG. 2;

FIG. 4 is an enlarged view area A of FIG. 3;

FIG. 5 is a disassembled perspective view of the full ice level sensing apparatus shown in FIG. 2;

FIG. 6 is an enlarged sectional view taken along the line VI-VI of FIG. 2;

FIG. 7 illustrates a full ice level sensing operation using the full ice level sensing apparatus of FIG. 2;

FIG. 8 is a block diagram of the ice maker of the refrigerator shown in FIG. 1; and

FIG. 9 is a disassembled perspective view of a full ice level sensing apparatus in accordance with another embodiment as broadly described herein.

DETAILED DESCRIPTION

As shown in FIG. 1, a refrigerator as embodied and broadly described herein may include a main body 110, doors 125 and 135, an ice maker 150 provided with the main body 110 or one of the doors 125 or 135, an ice bin or container 180 for storing the ice cubes made by the ice maker 150, an ice level sensing apparatus 220 provided with sensor elements 240 for sending or receiving a signal and an alignment device 250 for aligning and maintaining alignment of the sensor element 240 in a preset direction.

A freezing chamber 120 and a refrigerating chamber 130 for keeping food items in a frozen fresh state may be formed in the main body 110. The main body 110 may be a side by side type having the freezing chamber 120 and the refrigerating chamber 130 disposed next to each other in a horizontal direction. Alternatively, the main body 110 may be a top freezer or bottom freezer type having the freezing chamber 120 and the refrigerating chamber 130 one on top of the other disposed in a vertical direction.

The main body 110 may be provided with a refrigerating cycle device (not shown in detail) for providing cool air into the freezing chamber 120 and the refrigerating chamber 130. The refrigeration cycle device may employ a vapor compression type refrigerating cycle in which cool air is generated via a series of processes of compressing, condensing, expanding and evaporating a refrigerant.

The freezing chamber door 125 and the refrigerating chamber door 135 for opening and closing the freezing chamber 120 and the refrigerating chamber 130 may be rotatably coupled to front surfaces of the freezing chamber 120 and the refrigerating chamber 130, respectively. In the embodiment shown in FIG. 1, which is, simply for ease of discussion, a side by side type, the ice maker 150 for making ice cubes may be disposed at the freezing chamber door 125. In alternative embodiments, the ice maker 150 may be disposed within the main body 110. In other alternative embodiments, the ice maker 150 may be installed at an ice making chamber formed in a refrigerating chamber door (not shown). In any of these embodiments, the ice bin or container 180 for storing ice cubes made by the ice maker 150 may be positioned below the ice maker 150.

The ice maker 150 or the ice bin or container 180 may be provided with an ice level sensing apparatus 220 for sensing whether the ice bin or container 180 is at the full ice level. In this embodiment, an example in which the ice level sensing apparatus 220 is disposed at the ice maker 150 will be described. A dispenser 210 that dispenses ice cubes stored in the ice bin or container 180 to the outside may be disposed below the ice bin or container 180.

As shown in FIGS. 2 and 3, the ice maker 150 may include an ice tray 151 having a plurality of cells in which water is supplied to make ice cubes having a designated shape, a water supply 155 for supplying water into the ice tray 151, an ejector 161 for ejecting the ice cubes from the ice tray 151, a slider 167 oriented at an incline to guide the ice cubes ejected by the ejector 161, an ice separation heater for heating up the ice tray 151 to separate the ice cube made in each cell from the cell, a driver for driving the ejector 161, and a control box 170 for accommodating a controller which controls the driver and the ice separation heater.

The ejector 161 may include a shaft 163, and a plurality of ejector pins 165 that protrude radially from the shaft 163 and are spaced apart from one another in an axial direction along the length of the shaft 163. The ejector pins 165 may be aligned with the corresponding cells partitioned in the ice tray 151 so that, upon the rotation of the ejector 161, each of the ejector pins 165 rotates to apply pressure to and separate the ice cube from the corresponding cell, allowing the ice cube to be dropped out of the cell. A holder 175 for accommodating the ice separation heater therein may be disposed below the ice making tray 151.

The ice bin or container 180 may include a body 181 having an accommodation space therein. The body 181 may have an ice outlet 182 formed at its lower portion, a transfer screw (or auger) 183 rotatably disposed at a lower portion of the inside of the body 181, and an ice breaker 191 for breaking/crushing ice. The transfer screw 183 may be formed in a helical shape so as to direct ice towards the ice breaker 191.

The ice breaker 191 may include a plurality of fixed blades 193 fixed to the inside of the body 181, and a plurality of movable blades 195 that rotate relative to the fixed blades 193. Accordingly, ice cubes placed between the fixed blades 193 and the movable blades 195 are broken/crushed. A transfer screw driving motor 185 for rotating the transfer screw 183 may be disposed at one end portion of a shaft of the transfer screw 183.

An ice passage 212 that guides the ice downwardly may be formed at a lower side of the ice outlet 182 of the ice bin or container 180. The ice passage 212 may be connected to the dispenser 210. The ice passage 212 may be provided with a switching mechanism (not shown) for opening and closing the ice passage 212.

Various types of ice makers and operations thereof are disclosed in U.S. Pat. Nos. 7,210,299, 7,080,518, 7,017,354, 6,857,279, and 6,705,091, whose entire disclosures are incorporated herein by reference. These patents are also commonly assigned to the same assignee of this application.

With reference to FIGS. 2, 4 and 6, a transmitting unit or module 220 a is installed in a sensor housing or case 221, and a receiving unit or module 220 b is installed in a housing or case 221 at a portion extending from the holder 175 to correspond to the sensor case 221 of the transmitting unit or module 220 a. A transmitter 240 a and one or more receivers 240 b for transmitting and receiving signals may be installed in the transmitting unit or module 220 a and the receiving unit or module 220 b, respectively, to face each other. Based on the transmitted and received signals, the transmitting unit or module 220 a and the receiving unit or module 220 b are used to detect an ice-full state of the ice container 180. The ice level sensing apparatus 220 comprises at least one of the transmitter 240 a and the one or more of the receivers 240 b, and may further include transmitting and receiving units or modules 220 a, 220 b, and sensor housings 221, and is used to determine or detect ice full state of the ice container 180.

The sensing apparatus 120 may be disposed in or near the top, above or below the top of the ice container 180 at a position corresponding to the height at which ice is fully accumulated or collected. The transmitter and/or receiver may be optical devices to transmit or receive IR light. For example, the transmitter or emitter may be an IR photo diode and the receiver may be a photo transistor. The structure of the optical emitter or receiver is disclosed in U.S. Pat. No. 4,201,910, whose entire disclosure is incorporated herein by reference.

As shown in FIGS. 3 and 4, the receiving unit or module 220 b of the sensing apparatus 220 may extend in a downward direction down to the interior of the ice storage container 180. The receivers 240 b may be disposed at a position corresponding to the height of the ice-full state of the ice container 180. Although, the position of the receivers 240 b have been described, the transmitting unit or module 220 a and the transmitter 240 a may be formed to correspond to or near the height of the receiving unit or module 220 b and the receivers 240 b, as can be appreciated by one of ordinary skill in the art. In this embodiment, a detection height of the sensing apparatus 220 may have a certain height difference from an upper end or top ridgeline of the ice container 180.

The transmitting unit or module 220 a and the receiving unit or module 220 b of the sensing apparatus 220 are located at both sides of an ice discharging outlet, a passage through which ice is discharged from the ice maker. The receiver 240 b receives infrared rays transmitted from the transmitter 240 a, traversing the ice discharging outlet, and provide corresponding signals for determining whether the ice container 180 is substantially full of ice to detect the ice-full state. As can be appreciated, the location of the transmitting unit or module 220 a and the receiving unit or module 220 b may be reversed, i.e., receiver on the right and transmitter on the left.

In this embodiment, the transmitting unit or module 220 a and the receiving unit or module 220 b are separated by a prescribed distance which is less than a width of the ice container 180. Such lesser distance to the width allows the modules to be placed within the ice container 180. In an alternative embodiment, the distance may be greater than the width such that the modules may be located outside the ice container 180, which may have a cut-out to allow passage of the light or may be made of transparent material.

More specifically, the cases 221 of the ice level sensing apparatus 220 may include may each an accommodation space therein, with printed circuit boards (PCBs) 231 each accommodated in a corresponding case 221, and sensing (or optical) elements 240 (transmitters or receivers) for sending or receiving a signal provided on the PCBs 231, and alignment devices 250 for aligning and maintaining alignment of the sensing/optical elements 240 in a preset direction. Each sensing/optical element 240 may include the transmitter 240 a for sending a signal, and one or more receivers 240 b for receiving a signal, as described above.

The transmitter 220 a and the receiver 220 b may be spaced apart from each other by a preset distance. Alternatively, the transmitter 220 a and the receiver 220 b may be configured as a reflective sensing device, which is accommodated in the same case 221 and configured such that a signal, sent from the transmitter 220 a and then reflected on a target (in this embodiment, the target being an ice cube placed at a position of a full ice level) is received at the receiver 220 b.

Each case 221 may be formed integrally with the holder 175, so as to facilitate the connection with the ice maker 150, and the alignment between the transmitting unit or module 240 a and the receiving unit or module 240 b. Alternatively, each case 221 may be independently formed so as to be coupled to the holder 175. Also, the case 221 may be coupled to the ice bin or container 180. In certain embodiments, the case 221 may be positioned at a periphery of the ice bin or container 180 and then the ice bin or container 180 may be provided with a signal passing portion (e.g., a hole, a transparent window, etc.) through which a signal from the transmitting unit or module 240 a may be sent.

The transmitter 220 a of the sensing apparatus 220 may be provided with one of the PCBs 231, the transmitter 240 a of the electronic/optical element 240, and one of the alignment devices 250. The receiver 220 b of the sensing apparatus 220 may be provided with the other of the PCBs 231, the one or more receivers 240 b of the electronic/optical element 240, and the other alignment device 250. Accordingly, movement of the electronic/optical element 240, in more detail, the transmitter 240 a and the receiver 240 b, may be avoided, thereby improving reliability of the sensing function of the ice level sensing apparatus 220.

In certain embodiments, the transmitter 240 a and the receiver 240 b may be, for example, infrared sensors using infrared rays as signals. The transmitter 240 a may be a single component, and the receiver 240 b may include a plurality of components. In this embodiment, two receivers 240 b are spaced apart from each other. Accordingly, the signal sent from the single transmitter 240 a may be received at either of the two receivers 240 b, thereby forming a wider sensing area, resulting in further improvement in reliability of the sensing operation.

In certain embodiments, transmitter 240 a may output a pulse type signal at a designated interval. The receivers 240 b may be configured to output the number of received signals, or pulses, received from the transmitter 240 a as a signal having a preset voltage (level).

The transmitter 240 a and the receiver 240 b may be spaced apart from each other at a preset distance, and may be positioned at the full ice level within the ice bin or container 180. If the number of signals, or pulses, received by the receivers 240 b is greater than a set value, it is determined that the inside of the ice bin or container 180 is not at the full ice level. If the number of signals received is less than the set value, it is determined that the ice bin or container 180 is at the full ice level.

In more detail, as shown in FIG. 7, if ice is filled in the ice bin or container 180 up to the full ice level, a signal, or light, sent from the transmitter 240 a is blocked from reaching the receivers 240 b, or is reflected by the ice cubes, and thus the receivers 240 b cannot receive the signal from the transmitters 240 a. The receivers 240 b may be positioned vertically spaced apart from each other. Alternatively, the receivers 240 b may be horizontally spaced apart from each other.

Each alignment device 250 may be coupled to the corresponding PCB 231, which simplifies the configuration and facilitates fabrication and assembly, thereby reducing fabricating cost. Each PCB 231 may be provided with a circuit that allows the electronic/optical element 240 to send or receive a signal. Each of the alignment devices 250 may include an accommodation portion 251 in which the electronic/optical element 240 is received and coupled, and a coupling portion 255 formed at one end of the accommodation portion 251 which may be coupled to the corresponding PCB 231.

Each of the electronic/optical elements 240 (i.e., 240 a and 240 b) may be provided with a main body 241 having a substantially circular section, and a plurality of lead lines 243 extending from one side of the main body 241 to be mounted at the PCB 231. A protrusion 242 may extend outwardly from one end portion of the main body 241. A through hole 253 may be formed at the corresponding accommodation portion 251, at a position corresponding to the protrusion 242 so as to allow one end of the main body 241 to protrude outwardly. An accommodation space 254 may be formed within the accommodation portion 251 so as to accommodate the area of the protrusion 242.

The connection portion 255 may be provided with a plurality of coupling protrusions 257 coupled to the PCB 231. The coupling protrusions 257 may each extend from an end portion of the accommodation portion 251 in a lengthwise direction and may be spaced apart from one another in a circumferential direction. For example, the embodiment shown in FIGS. 5 and 6 employs four coupling protrusions 257. The coupling protrusions 257 may be elastically deformable to allow the coupled state with the PCB 231 to be firmly maintained. A stopper 258 may be formed at an end portion of each coupling protrusion 257 to prevent sudden separation of the coupling protrusion 257 after it is coupled to the PCB 231. A slanted guiding surface 259 may be formed at one side of each stopper 258.

Corresponding to this configuration, the PCB 231 may be provided with insertion holes 233 formed therethrough such that the coupling protrusions 257 may be inserted therein and coupled to the PCB 231. Each insertion hole 233 may extend inwardly through the PCB 231 and be sized such that the corresponding coupling protrusion 257 may be inserted in the insertion hole 233 and be elastically deformed. Accordingly, upon inserting the coupling protrusions 257, the guiding surface 259 comes in contact with the insertion hole 233, deforming the coupling protrusion 257 and allowing the coupling protrusion 257 to slide through the insertion hole 233. After it extends all the way through to the opposite side of the PCB 231, the coupling protrusion 257 is restored to its original state by its own elastic force, so as to elastically come in contact with an inner surface of the insertion hole 233. The stopper 258 is stopped at an outer edge of the insertion hole 233, thereby preventing the coupling protrusion 257 from being unexpectedly separated from the insertion hole 233.

Each of the cases 221 may be provided with an accommodation space 223 having one side open. A cover 225 may be disposed at the open side of the case 221. A sealing member 227 may be disposed between the case 221 and the cover 225. The sealing member 227 may be formed of an elastic material (e.g., rubber, silicon, or the like) with elasticity. The sealing member 227 may prevent external moisture from entering into the accommodation space 223 through a space between the case 221 and the cover 225, preventing damage to the electronic element 240 due to freezing of moisture.

Each of the covers 225 may be provided with a transparent window through which a signal from the transmitter 240 a may be sent and received by the receiver 240 b. In certain embodiments, the entire cover 225 may be made of a transparent material, and thus the cover 225 may also serve the function of the transparent window. Alternatively, a part of the cover 225, i.e., an area corresponding to the front surface of the electronic/optical element 240, may be configured as the transparent window.

The case 221 or the cover 225 may be provided with a temperature rising portion 261, or heater, for increasing the temperatures of the electronic/optical element 240 and the cover 225 (substantially, at least the transparent window of the cover 225) to prevent frosting. Hence, signal degradation (e.g., interference, distortion, and the like) due to frosting may be prevented, resulting in improvement of sensing reliability.

The temperature rising portion 261, or heater, may be, for example, an electric heater or a plate-type heater with a relatively thin thickness (e.g., in the form of a film or sheet, and may operate by receiving power applied every time the main body 110 operates. The temperature rising portion 261 may have a thermal value great enough to prevent frosting on the electronic element 240 and the cover 225 (transparent window). In certain embodiments, the temperature rising portion 261 may be supported by a supporting portion 228 provided at the rear surface of the cover 225, as shown in FIG. 6.

As shown in FIG. 8, the refrigerator in accordance with this embodiment as broadly described herein may include a controller 265 implemented as, for example, a microprocessor having a control program for controlling the ice making process. The ice level sensing apparatus 220, which senses whether the ice bin or container 180 is at the full ice level so as to control the ice making process of the ice maker 150, a driver 267 and an ice separation device 269, such as, for example, a heater, may be connected to the controller 245 so that the controller 265 can control these components. In more detail, the PCB 231 to which the transmitter 240 a of the ice level sensing apparatus 220 is connected, the PCB 231 to which the plurality of receivers 240 b are connected, and the temperature rising portion (i.e., heater) 261 may all be connected to the controller 265.

During operation, water is supplied into the ice tray 151 via the water supply 155. After a preset period of time (i.e., a time required for freezing the water) elapses, the controller 265 determines whether the ice bin or container 180 is at the full ice level based upon a sensing signal from the ice level sensing apparatus 220. If it is determined that the ice bin or container 180 is not at the full ice level, the controller 265 then applies power to the ice separation device 269 to separate ice from the ice tray 151 and deposit it into the ice bin or container 180, and continue the ice making process.

When power is applied to the ice separation device 269, outer surfaces of the ice cubes within the ice tray 151 are slightly melted by the ice separation heater and thus the ice cubes are separated from the ice tray 151. The controller 265 controls the driver 267 such that the ejector 161 can rotate in order to eject the separated ice cubes and store them in the ice bin or container 180. When the ejector 161 rotates, the separated ice cubes from the ice tray 151 are pushed upwardly by the ejector pins 165 and dropped down into the ice bin or container 180 along the upper surface of the slider 167.

Meanwhile, if the ice level sensing apparatus 220 senses that the ice bin or container 180 is at the full ice level, then the controller 265 stops the operation of the ice separation device 269 and the driver 267 and suspends the ice making process.

Hereinafter, an ice level sensing apparatus for a refrigerator in accordance with another embodiment as broadly described herein will be discussed with reference to FIG. 9.

As shown in FIG. 9, an ice level sensing apparatus 320 may include cases 321 each forming an accommodation space therein, printed circuit boards (PCB) 331 each accommodated in a corresponding case 321, an electronic/optical element 240 for sending or receiving a signal disposed at the PCB 331, and alignment devices 250 for aligning and maintaining alignment of the electronic elements 240 towards a preset direction. Each electronic/optical element 240 may include a transmitter 240 a for sending a signal, and a receiver 240 b for receiving a signal sent from the transmitter 240 a. The transmitter 240 a and the receiver 240 b may be infrared sensors for sending and receiving infrared signals.

The transmitter 240 a and the receiver 240 b may be coupled to separate PCBs 331 by separate alignment devices 250 and then accommodated in the separate cases 321. Alternatively, the transmitter 240 a and the receiver 240 b may be aligned at a single PCB 331 by separate alignment units 250 and accommodated in a single case 321.

Hereinafter, for purposes of discussion, it will be assumed that the transmitter 240 a and the receiver 240 b are aligned at the separate PCBs 331 by separate alignment devices 250 and accommodated in separate cases 321. The detailed description of the ice level sensing apparatus having the transmitter 240 a may be understood by the aforementioned embodiment, and hereinafter, the ice level sensing apparatus having the receivers 240 b as shown in FIG. 9 will be described.

As shown in FIG. 9, two electronic/optical elements 240 are provided on one PCB 331. The electronic/optical element 240, as described above, may include the receivers 240 b for receiving a signal from the transmitter 240 a. Accordingly, a sensing area for one signal may be extended so as to improve sensing reliability.

The two electronic/optical elements 240 are spaced apart from each other on the PCB 331. Insertion holes 333, to which the alignment devices 250 are coupled, may be formed through the PCB 331 corresponding to the peripheries of the electronic/optical elements 240.

Each of the alignment devices 250 may be provided with an accommodation portion 251 in which the corresponding electronic/optical element 240 is accommodated, and a coupling portion 255 for coupling the accommodation portion 251 to the PCB 331.

The coupling portion 255 may include a plurality of coupling protrusions 257 which are elastically deformable. Each of the coupling protrusions 257 may have a stopper 258 and a guiding surface 259 that is inclined in an insertion direction at one end of the stopper 258.

The case 321 may have an upwardly open accommodation space. A transparent window 323, through which a signal sent from the transmitter 240 a may be sent/received, may be formed at one side of each case 321.

Guide slots 324 for guiding the accommodation and alignment of the PCB 331 having the electronic/optical element 240 coupled thereto may be formed in each case 321. Guide protrusions 325 may be formed at two opposite side regions within the case 321 to define the guide slots 324. The guide slots 324 may to be positioned in the case 321 such that two opposite end portions of the PCB 321 can be slidably inserted.

A coupling device 327 for coupling the corresponding case 321 to the ice maker 150 using, for example, a coupling member (not shown) such as a screw, may be formed at one side of the case 321 such as, for example, an upper side of the case 321 in this embodiment. Alternatively, a plurality of coupling devices 327 may be provided at side portions of the case 321 to fix the case 321, for example, to an inner side wall of the ice bin or container 180.

A sealing cap 333 for sealing the inside of the case 321 from the outside thereof may be disposed at an opened upper portion of the case 321. Therefore, external moisture can be prevented from entering the case 321, thereby avoiding an adverse effect due to moisture.

The transparent window 323 may be formed at one side of the case 321. At one region of the rear surface of the transparent window 323, a temperature rising portion, i.e., an electric heater 261, may be provided to increase an internal temperature and prevent the electronic/optical elements 240 and the transparent window 323 from frosting. The heater 261 may generate heat upon power being applied thereto and may be, for example a plate-type heater.

When so configured, the end portion of the electronic element 240 mounted at the PCB 331 is inserted in the alignment unit 250, and also the end portion of each coupling protrusion 257 of the corresponding alignment device 250 is inserted in the corresponding insertion hole 333 of the PCB 331. Each coupling protrusion 257 is elastically deformed as the insertion hole 333 comes in contact with the inclined guiding surface 259, and then restored to its initial position by its own elastic force after being inserted through the insertion hole 333. Accordingly, the alignment device 250 can be prevented from being unexpectedly separated from the PCB 321.

Upon power being applied thereto, the heater 261 emits heat to increase the temperature of the transparent window 323 and the electronic/optical element 240, so as to prevent degradation in signal sensitivity (e.g., damage, refraction, distortion, and the like) due to the frosting of the electronic/optical element 240 and the transparent window 323, thereby enhancing reliability of sensing the ice level of ice cubes in the ice bin or container 180.

As described above, in accordance with one embodiment as broadly described herein, by employing an alignment unit for aligning an electronic/optical element in a preset direction and maintaining the aligned state of the electronic element, the electronic/optical element can be prevented from being loosened (moved, shaken), and thus its reliability in sensing the ice full level can be improved.

Also, the alignment device may have an accommodation portion for accommodating the electronic/optical element and a coupling portion for fixing a target to one side of the accommodation portion, so as to allow for a simple configuration and facilitate fabrication and assembly, resulting in improvement of sensing reliability with low fabricating cost.

Also, a heater can further be provided for preventing the frosting of the electronic element, so as to further improving the sensing reliability.

A refrigerator is provided that is capable of enhancing reliability of sensing as to whether ice cubes are fully filled in an ice bin or container, and a full ice level sensing apparatus for the refrigerator.

A refrigerator is provided that is capable of implementing a simple configuration with low fabricating cost and enhancing reliability of a sensing as to whether ice cubes are fully contained, and a full ice level sensing apparatus therefor.

A refrigerator as embodied and broadly described herein may include a refrigerator main body and a door; an ice maker disposed at the refrigerator main body or the door and configured to make ice cubes; an ice bin or container configured to store the ice cubes made by the ice maker; and a full ice level sensing apparatus provided with an electronic element unit for sending or receiving a signal, and alignment units for aligning and maintaining the electronic element unit in a preset direction, and configured to sense whether the ice bin or container is fully filled with the ice cubes.

The electronic element unit may include a sending portion for sending a signal and a receiving portion for receiving the signal.

The full ice level sensing apparatus may be disposed at the ice maker.

The sending portion and the receiving portion may be mounted at different printed circuit boards (PCBs), respectively, wherein the alignment units are coupled to the corresponding PCBs.

Each of the alignment units may include an accommodation portion in which the sending portion and the receiving portion are accommodated, and a coupling portion formed at one side of the accommodation portion and coupled to the corresponding PCB.

The coupling portion may include a plurality of coupling protrusions.

Each of the coupling protrusions may include a stopper configured to come in contact with the corresponding PCB to prevent the coupling protrusion from being separated.

The coupling protrusion may be elastically transformable.

The sending portion may be configured as a single part and the receiving portion may be provided in plurality.

The full ice level sensing apparatus may further include a temperature rising portion configured to rise the temperature of the electronic element unit.

The full ice level sensing apparatus may further include case and cover both for accommodating the electronic element unit and the alignment unit, respectively, the cover having a transparent window.

The temperature rising portion may be disposed at the cover.

A full ice level sensing apparatus for a refrigerator as embodied and broadly described herein may include a case forming an accommodation space therein; a printed circuit board (PCB) accommodated in the case; an electronic element unit configured to send or receive a signal, and mounted at the PCB; and an alignment unit configured to align and maintain the electronic element unit in a preset direction.

The case may be provided with an opening through which the PCB is accommodated, and the apparatus may further include a sealing cap configured to seal the opening of the case.

The apparatus may further include a heater configured to rise the temperature of the electronic element unit.

The case may be provided with a transparent window, and the heater may be disposed at one side of the transparent window.

A full ice level sensing apparatus for a refrigerator as embodied and broadly described herein may include sending unit and receiving unit, spaced from each other, each having a case forming an accommodation space therein, and a printed circuit board (PCB) disposed in the case, for sensing whether an ice bin or container storing ice cubes made by an ice maker is fully filled with the ice cubes, wherein the sending unit comprises an electronic element unit mounted at the PCB of the sending unit for sending a signal, and an alignment unit for aligning and maintaining the electronic element unit in a preset direction, wherein the receiving unit comprises an electronic element unit mounted at the PCB of the receiving unit for receiving a signal, and an alignment unit for aligning and maintaining the electronic element unit in a preset direction.

Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, numerous variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. 

1. A refrigerator, comprising: a main body; a door coupled to the main body; an ice maker installed in the main body or the door; a storage container configured to receive and store the ice cubes made by the ice maker; and a sensing apparatus configured to sense an ice level in the storage container, the sensing apparatus comprising: an optical element that sends or receives a signal; and at least one alignment device that aligns and secures the optical element in a preset direction.
 2. The refrigerator of claim 1, wherein the optical element comprises: a transmitting module that sends a signal; and a receiving module that receives the signal sent by the transmitting module.
 3. The refrigerator of claim 1, wherein the sensing apparatus is disposed at the ice maker.
 4. The refrigerator of claim 2, wherein the transmitting module and the receiving module are coupled to first and second printed circuit boards (PCBs), respectively, and wherein the at least one alignment device comprises first and second alignment devices that couple the transmitting and receiving modules to the first and second PCBs, respectively.
 5. The refrigerator of claim 4, wherein each of the alignment devices comprises: an accommodation portion in which a respective transmitting or receiving module is accommodated; and a coupling portion formed at one end of the accommodation portion so as to couple the accommodation portion to the corresponding PCB.
 6. The refrigerator of claim 5, wherein the coupling portion comprises a plurality of coupling protrusions.
 7. The refrigerator of claim 6, wherein each of the coupling protrusions comprises a stopper configured to contact the corresponding PCB so as to prevent the separation of the plurality of coupling protrusions from the corresponding PCB.
 8. The refrigerator of claim 6, wherein each of the coupling protrusions is elastically deformable.
 9. The refrigerator of claim 2, wherein the transmitting module comprises a single transmitter and the receiving module comprises a plurality of receivers.
 10. The refrigerator of claim 9, wherein the single transmitter is positioned on a first side of the ice maker and the plurality of receivers are positioned on a second side of the ice maker opposite the first side, and wherein the plurality of receivers are spaced apart from each other on the second side of the ice maker so as to form a receiving range in which the signal from the single transmitter is received.
 11. The refrigerator of claim 1, wherein the sensing apparatus further comprises a temperature regulator configured to increase a temperature of the optical element.
 12. The refrigerator of claim 11, wherein the temperature regulator comprises a heater configured to increase the temperature of the optical element.
 13. The refrigerator of claim 11, wherein the sensing apparatus further comprises case in which the optical element and the at least one alignment device are received, and a cover that covers and open face of the case, the cover having a transparent window.
 14. The refrigerator of claim 13, wherein the temperature regulator is positioned adjacent to the cover.
 15. An ice level sensing apparatus for a refrigerator that senses whether a storage container that stores ice cubes made by an ice maker is fully filled with ice cubes, the apparatus comprising: a case having an accommodation space formed therein; a printed circuit board (PCB) received in the accommodation space; an optical element mounted at the PCB and configured to send or receive a signal; and an alignment device configured to align and maintain alignment of the optical element in a preset direction.
 16. The apparatus of claim 15, wherein the case is provided with an opening through which the PCB is positioned in the accommodation space, and wherein the apparatus further comprises a sealing cap that covers and seals the opening.
 17. The apparatus of claim 15, further comprising a heater configured to increase a temperature of the optical element.
 18. The apparatus of claim 17, wherein the case includes a transparent window, and the heater is positioned at one side of the transparent window.
 19. An ice level sensing apparatus for a refrigerator, the sensing apparatus comprising a transmitter and a receiver spaced apart from each other, each having a case with an accommodation space formed therein and a printed circuit board (PCB) disposed in the case, wherein the sensing apparatus senses whether a container storing ice cubes made by an ice maker is fully filled with ice cubes, wherein the transmitter comprises a first electronic element mounted at a corresponding PCB thereof, and a first alignment device that aligns and secures the first electronic element in a first preset direction, and wherein the receiver comprises a second electronic element mounted at a corresponding PCB thereof, and a second alignment device that aligns and secures the second electronic element in a second preset direction. 